Process for making an absorbent article having inflected barrier leg cuff

ABSTRACT

A process for making a wearable, absorbent article is described wherein two longitudinally extending barrier leg cuffs are attached to a chassis and the barrier leg cuffs are joined to the article so that they are directed inwardly toward a longitudinally extending centerline in the first waist region of the article and directed outwardly away from the longitudinally extending centerline in the second waist region of the article. The method describes the cuffs as being first attached in the first waist region and then in the second waist region in one embodiment and, in another embodiment, being attached in the second waist region first and then in the first waist region of the article. A process is also described for making a wearable, absorbent article wherein the barrier leg cuffs are attached to the article outboard of the longitudinally extending centerline in both the first waist and second waist regions of the article and wherein the barrier leg cuffs are joined partially to the article in the crotch region.

This is a divisional of application Ser. No. 08/260,638, filed Jun. 16,1994, now U.S. Pat. No. 5,496,428.

FIELD OF THE INVENTION

The present invention relates to a method for making absorbent articlessuch as disposable diapers, and more particularly, to absorbent articleshaving barrier cuffs which improve the containment characteristics andfit of the absorbent article.

BACKGROUND OF THE INVENTION

The major function of absorbent articles such as disposable diapers andincontinent briefs or undergarments is to absorb and contain bodyexudates. Such articles are thus intended to prevent body exudates fromsoiling, wetting, or otherwise contaminating clothing or other articles,such as bedding, that come in contact with the wearer. The most commonmode of failure for such products occurs when body exudates leak out ofthe gaps between the article and the wearer's leg or waist to adjacentclothing because they are not immediately absorbed within the articleand the absorbent article is not able to sustain a good fit on thewearer such that gaps are created allowing the exudates to leak out ofthe chassis of the absorbent article. For example, urine tends to bedeposited onto the topsheet in gushes such that the urine migrates tothe gaps in the chassis where it can come in contact with clothing orother articles and be absorbed by these articles. Additionally, loosefecal material that is not easily absorbed by the absorbent articletends to "float" on the liquid-receiving surface and work its way pastthe gaps in the article in the legs or waist of the wearer.

Contemporary disposable diapers have a topsheet, a backsheet, anabsorbent core, and elasticized leg flaps generally formed from anelastic member being enclosed in the continuous topsheet and backsheetwhich extend beyond the edges of the absorbent core. These elasticizedleg flaps prove efficient generally to prevent wicking and overflow fromthe fluid laden diaper to clothing contacting the edges of the diaper inthat the elasticized leg flaps present a fluid impervious barrierbetween the edge of the diaper and the contacting clothing, and inaddition, provide a gasketing action about the legs of the wearer tomaintain a seal about the leg and minimize gapping. However, leakagealong the perimeter of the diaper may still occur. As the diaper is wornfor longer periods of time, forces tend to act on the diaper to degradethe initial fit on the wearer. Large gaps and sagging of the diaper inthe legs and waist are formed by the degradation in fit. Thus, asliquids are deposited onto the topsheet, some of the liquid is notimmediately absorbed through the topsheet and migrates toward the edgesof the diaper where it can leak through or past the gaps in the diaperand come in contact with clothing or undergarments where it can beabsorbed by and wicked into such garments.

Disposable diapers may be provided with barrier cuffs which inhibitloose fecal material or gushes of urine or liquids from soiling thewearer's clothing. The barrier cuffs restrain the free flow of thismaterial and provide a structure to hold such material within the diaperso that as such material freely floats or flows on the topsheet of thediaper, it is contained within the diaper. Despite the effectiveness ofsuch structures in containing such material, it has been found thatliquids can leak beyond the barrier cuffs and soil the wearer's clothingbecause the diaper construction does not promote a sustained fit of thediaper on the wearer. Additionally, the barrier cuffs may not beproperly applied to the wearer such that good initial fit is notachieved and the sustained fit is often worse.

SUMMARY OF THE INVENTION

This invention relates to an improved method for making a disposableabsorbable article having an inflected barrier leg cuff. This garmentconsists of a chassis which includes a topsheet, a backsheet and anabsorbent core between the topsheet and the backsheet. The articlefurther has a first waist region, a second waist region, and a crotchregion located between the first and second waist regions.

In this method, barrier leg cuffs are attached to the topsheet of thearticle, one on each side of a longitudinal centerline. To allow forcutting of leg notches without interference from the barrier leg cuffs,the border cuffs are folded inwardly toward the longitudinal centerlineof the article. After the leg notches are cut and removed, the barrierleg cuffs are attached in the second waist region directed outwardlyfrom the longitudinal centerline. Next, the barrier leg cuffs are foldedinwardly toward the longitudinal centerline and joined to the chassis atthe first waist region of the article. Finally, the article is foldedand then separated for packaging. This entire process can be carried outin one machine direction thus eliminating the need for changing machinedirection or refeeding the article into the assembly line.

In a second embodiment of this invention, the barrier leg cuffs arefirst attached to the topsheet on each side of the longitudinalcenterline. Next, the barrier leg cuffs are secured to the topsheet inthe first waist region of the article so that they are directed inwardlytoward the longitudinal centerline. Then the chassis is formed and theleg notches are cut forming ear panels in the first and second waistregions. Next, the ear panels in the second waist region are foldedinwardly toward the longitudinal centerline and over the barrier legcuffs to which the ear panels are joined. Finally, the article is cut toprepare it for shipment.

In a third embodiment of this invention, the barrier leg cuffs are firstattached to the topsheet on each side of the longitudinal centerline.They are then attached at the second waist region of the article so thatthey are folded outwardly of the centerline. Next, the chassis is formedin any conventional manner. Once the chassis has been formed, the legnotches are cut. Then, a bonding agent is applied to the interior sideof the distal portion of the barrier leg cuffs in the first waist regionof the article. The article is folded and separated into separatearticles. In a fourth embodiment of this invention, the barrier legcuffs are first attached to the topsheet. They are secured in the firstand second waist regions so that both leg cuffs are either directedoutwardly of the centerline or inwardly toward the longitudinalcenterline. After the barrier leg cuffs are secured in the first andsecond waist regions, they are partially secured in the crotch region toprovide a stand up barrier in that region. The article is then foldedand prepared for shipment.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter which is regarded as formingthe present invention, it is believed that the invention will be betterunderstood from the following descriptions which are taken inconjunction with the accompanying drawings in which like designationsare used to designate substantially identical elements, and in which:

FIG. 1 is a plane view of the diaper made by the process of thisinvention;

FIG. 2 presents an illustration of one embodiment of the process of thisinvention;

FIG. 2A presents a continuing illustration of the process presented inFIG. 2;

FIG. 3 presents an illustration of a second embodiment of the process ofthis invention;

FIG. 4 presents an illustration of a third embodiment of the process ofthis invention; and

FIG. 5 presents an illustration of a fourth embodiment of the process ofthis invention; and

FIG. 6 presents a diagrammatic illustration of the basic process of thisinvention.

DETAILED DESCRIPTION OF THE INVENTION The Product

As used herein, the term "absorbent article" refers to articles whichabsorb and contain body exudates and more specifically refers toarticles which are placed against or in proximity to the body of thewearer to absorb and contain the various exudates discharged from thebody. Absorbent articles are typically differentiated by whether theyare reusable or disposable. Disposable absorbent articles are thosearticles which are intended to be discarded after a single use (i.e.,they are not intended to be laundered or otherwise restored or reused).The absorbent articles of the present invention are preferablydisposable absorbent articles. The absorbent articles may be furtherdefined by whether they are "unitary" such that they do not requireseparate manipulative parts or whether they comprise an element of adiaper system such as a separate holder and liner. The absorbentarticles of the present invention are preferably unitary. A preferredembodiment of a unitary disposable absorbent article of the presentinvention, diaper 20, is shown in FIG. 1. As used herein, the term"diaper" refers to a garment generally worn by infants and incontinentpersons that is worn about the lower torso of the wearer. It should beunderstood, however, that the present invention is also applicable toother disposable absorbent articles such as incontinence briefs orundergarments, disposable training pants, diaper holders, sanitarynapkins, and the like.

FIG. 1 is a plane view of the diaper 20 of the present invention in itsflat-out, uncontracted state (i.e., with all elastic induced contractionpulled out) with portions of the structure being cut-away to moreclearly show the construction of the diaper 20 and with the portion ofthe diaper 20 which contacts the wearer facing the viewer. The diaper 20is shown in FIG. 1 to have a first waist region 22, a second waistregion 24, a crotch region 26, and a periphery 28 which is defined bythe outer edges of the diaper 20 in which the longitudinal edges aredesignated 30 and the end edges are designated 32. The diaper 20additionally has a lateral centerline which is designated 34 and alongitudinal centerline which is designated 36.

The diaper 20 comprises a liquid pervious topsheet 38, theliquid-receiving surface of the diaper 20 being generally defined by thetopsheet 38 and being designated 40; a liquid impervious backsheet 42;an absorbent core 44 having a garment surface 46, a body surface 48, andedges that are designated side edges 50 and waist edges 52; fasteningmeans 54 for securing the diaper 20 on the wearer such as the pair oftape tab fasteners 56; a side flap 58 extending outwardly from each sideedge 50 of the absorbent core 44 in at least the crotch region 26; earflaps 100; barrier cuffs 62 each having a proximal edge 64, a distaledge 66, a first end 72, and a second end 74; spacing means 76 such aselastic members 77 for spacing the distal edge 66 away from theliquid-receiving surface 40; first closing means 78 for securing aportion of the distal edge 66 inboard of the proximal edge 64; andsecond closing means 80 for securing a portion of the distal edge 66outboard of the proximal edge 64.

FIG. 1 shows an embodiment of the diaper 20 in which the backsheet 42has length and width dimensions generally larger than those of theabsorbent core 44. The backsheet 42 extends beyond the edges of theabsorbent core 44 to thereby form the periphery 28 of the diaper 20. Theperiphery 28 defines the outer perimeter or, in other words, the edgesof the diaper 20. The periphery 28 comprises the longitudinal edges 30and the end edges 32. As shown in FIG. 1, the topsheet 38 is generallycoterminous with the backsheet 42 along at least the end edges 32 andpreferably the longitudinal edges 30.

The diaper 20 has a first waist region 22 and a second waist region 24extending, respectively, from the end edges 32 of the diaper periphery28 toward the lateral centerline 34 of the diaper 20 a distance up toabout 1/3, preferably from about 1/8 to about 1/4, of the length of thediaper 20. The waist regions 22 and 24 generally comprise those portionsof the diaper 20 which, when worn, encircle the waist of the wearer. Thecrotch region 26 is that portion of the diaper 20 positioned between thefirst waist region 22 and the second waist region 24, and comprises thatportion of the diaper 20 which, when worn, is positioned between thelegs of the wearer and covers the lower torso of the wearer.

The absorbent core 44 may be any means which is generally compressible,conformable, non-irritating to the wearer's skin, and capable ofabsorbing and retaining liquids and certain body exudates. A preferredabsorbent core 44 has a garment surface 46 and a body surface 48.

The absorbent core 44 may be manufactured in a wide variety of sizes andshapes (e.g., rectangular, hour-glass, asymmetric, etc.) and from a widevariety of liquid absorbent materials commonly used in disposablediapers and other absorbent articles, such as comminuted wood pulp whichis generally referred to as air-felt. Examples of other suitableabsorbent materials include creped cellulose wadding, absorbent foams,absorbent sponges, super absorbent polymers, absorbent gellingmaterials, or any equivalent materials or combination of materials. Thetotal absorbent capacity of the absorbent core 44 should, however, becompatible with the design exudate loading in the intended use of thediaper 20. The size and absorbent capacity of the absorbent core 44 maybe varied to accommodate wearers ranging from infants through adults.

The backsheet 42 is positioned adjacent the garment surface 46 of theabsorbent core 44 and is preferably secured thereby by core attachmentmeans (not shown) such as those well known in the art. For example, thebacksheet 42 may be secured to the absorbent core 44 by a uniformcontinuous layer of adhesive, a patterned layer of adhesive, or an arrayof separate lines or spots of adhesive. The core attachment meanspreferably comprises an open pattern network of filaments of adhesive.

The backsheet 42 is impervious to liquids and is preferably manufacturedfrom a thin plastic film, although other flexible liquid imperviousmaterials may also be used. The backsheet 42 prevents the exudatesabsorbed and contained in the absorbent core 44 from wetting articleswhich contact the diaper 20 such as bedsheets and undergarments.Preferably, the backsheet 42 is a polyethylene film having a thicknessof from about 0.012 mm (0.5 mil) to about 0.051 cm (2.0 mils), althoughother flexible, liquid impervious materials may be used. As used herein,the term "flexible" refers to materials which are compliant and whichwill readily conform to the general shape and contours of the humanbody. The backsheet 42 is preferably embossed and/or matte finished toprovide a more clothlike appearance. The backsheet 42 may permit vaporsto escape from the absorbent core 44 while still preventing exudatesfrom passing through the backsheet 42. The size of the backsheet 42 isdictated by the size of the absorbent core 44 and the exact diaperdesign selected.

The topsheet 38 is compliant, soft feeling, and non-irritating to thewearer's skin. The topsheet 38 is liquid pervious permitting liquids toreadily penetrate through its thickness. A suitable topsheet may bemanufactured from a wide range of materials, such as porous foams,reticulated foams, apertured plastic films, natural fibers (e.g., woodor cotton fibers), synthetic fibers (e.g. polyester or polypropylenefibers) or from a combination of natural and synthetic fibers.Preferably, it is made of a hydrophobic material to isolate the wearer'sskin from liquids in the absorbent core 44. If the topsheet 38 is madeof a hydrophobic material, at least the upper surface of the topsheet 38is treated to be hydrophilic so that liquids will transfer through thetopsheet more rapidly. This diminishes the likelihood that body exudateswill flow off the topsheet 38 rather than being drawn through thetopsheet 38 and being absorbed by the absorbent core 44. The topsheet 38can be rendered hydrophilic by treating it with a surfactant. Suitablemethods for treating the topsheet 38 with a surfactant include sprayingthe topsheet 38 material with the surfactant and immersing the materialinto the surfactant. A more detailed discussion of such a treatment andhydrophilicity is contained in U.S. Pat. No. 4,988,344 entitled"Absorbent Articles with Multiple Layer Absorbent Layers" issued toReising, et al on Jan. 29, 1991 and U.S. Pat. No. 4,988,345 entitled"Absorbent Articles with Rapid Acquiring Absorbent Cores" issued toReising on Jan. 29, 1991, each of which is incorporated by referenceherein.

There are a number of manufacturing techniques which may be used tomanufacture the topsheet 38. For example, the topsheet 38 may be woven,non-woven, spunbonded, carded, or the like. A preferred topsheet 38 iscarded, and thermally bonded by means well known to those skilled in thefabrics art. Preferably, the topsheet 38 has a weight from about 18 toabout 25 grams per square meter, a minimum dry tensile strength of atleast about 400 grams per centimeter in the machine direction and a wettensile strength of at least about 55 grams per centimeter in the crossmachine direction.

The side flaps 58 are that portion of the diaper 20 between theperiphery 28 and the side edges 50 of the absorbent core 44. Thus, in apreferred embodiment as shown in FIG. 1, the side flaps 58 are formedfrom the extension of the backsheet 42 and the topsheet 38 extendingoutwardly from and along the side edges 50 of the absorbent core 44 ofthe diaper 20 in at least the crotch region 26.

The diaper 20 is provided with a fastening means 54 for forming a sideclosure in the diaper 20. Thus, the diaper 20 is fitted to the wearerand preferably the first waist region 22 and the second waist region 24are maintained in an overlapping configuration when the diaper 20 isworn. While the fastening means 54 may comprise any of a number offastening systems as are known in the art such as belts or innerfastening members, in a preferred embodiment the fastening means 54comprises a tape tab 56 disposed adjacent each longitudinal edge 30 ofthe diaper 20 preferably in the second waist region 24. Tape tabfasteners 54 are preferably applied to the second waist region 24 of thediaper 20 to provide a fastening means 54 to hold the diaper 20 to thewearer, although they may alternatively be disposed in the first waistregion 22. The tape tab fasteners 54 can be any of those tape tabs wellknown in the art.

The barrier leg cuffs 62 provide a structure to restrain the free flowof body exudates along the liquid-receiving surface 40 and to hold andcontain such exudates within the diaper 20 and to provide a gasketingaction about the wearer. Each barrier cuff 62 is a flexible memberhaving a proximal edge 64 and a distal edge 66. In addition, if thespacing means 76 comprises one or more elastic members 77, the barriercuffs 62 must be contractible so that the distal edges 66 may besufficiently spaced away from the liquid-receiving surface 40 to form achannel and may provide a gasketing action about the buttocks of thewearer. The barrier cuffs 62 may be manufactured from a wide variety ofmaterials such as polypropylene, polyester, rayon, nylon, foams, plasticfilms, formed films, elastic laminates and elastic foams. A number ofmanufacturing techniques may be used to manufacture the barrier cuffs.For example, the barrier cuffs 62 may be woven, non-woven, spunbonded,carded, or the like. A particularly preferred barrier cuff 62 comprisesa laminate of a non-woven polypropylene material secured to a liquidimpermeable polyethylene film. The materials may be secured or laminatedto each other by any methods as is known in the art.

The barrier cuff 62, and more particularly, the proximal edge 64, isdisposed adjacent to and preferably inboard of the longitudinal edge 30of the diaper 20. The term "inboard" is defined as the direction towardthe centerline (34 or 36, respectively) of the diaper 20 that isparallel to the respective edge of the diaper 20 along which theparticular barrier cuff is disposed. The proximal edge 64 is preferablydisposed inboard of the longitudinal edge 30 so that exudates,especially loose fecal material which is not easily absorbed and tendsto float along the liquid-receiving surface 40, will contact the barriercuff 62 before it can contact the edges of the diaper 20. Thus, theproximal edge 64 is preferably disposed between the longitudinal edge 30and the longitudinal centerline 36 of the diaper 20. Most preferably,the proximal edge 64 is disposed between the longitudinal edge 30 andthe side edges 50 of the absorbent core 44 in at least the crotch region26 of the diaper 20. (It should be noted that if the side flaps 58 areelasticized by one or more flap elastic members to form a gasketing cuffadjacent each longitudinal edge 30, as is known in the art, then theproximal edge 64 is preferably positioned between the innermost flapelastic member and the side edge 50 of the absorbent core 44 in at leastthe crotch region 26.)

The proximal edges 64 and the distal edges 66 are in a spaced relationto each other and define the effective width of each of the barriercuffs 62. The proximal edges 64 and the distal edges 66 may be in aparallel, nonparallel, rectilinear or curvilinear relationship. Inaddition, each of the barrier cuffs 62 may have a variety of differentcross-sectional areas including circular, square, rectangular, or anyother shape. Preferably, the proximal edge 64 is spaced from the distaledge 66 in a parallel and rectilinear relationship. The effective widthof the barrier cuff 62 is an important parameter in reducing leakage ofbody exudates out of the diaper 20. If the effective width of thebarrier cuff 62 is too small, then gaps will be formed between the legof the wearer and the distal edge 66 such that liquids may flow over thedistal edge 66 to the periphery 28 of the diaper 20. The effective widthshould be dimensionalized as the size of the wearer increases ordecreases, particularly with adult wearers.

The distal edge 66 of each barrier cuff 62 is preferably not secured toany underlying elements of the diaper 20 in at least the crotch region26 so that it may be spaced away from the liquid-receiving surface 40.The distal edge 66 is preferably spaced away from the liquid-receivingsurface 40 so that the barrier cuff 62 may form a channel to enhance thecontainment of the diaper 20. As used herein, "spaced" includesembodiments wherein the distal edges 66 may assume one or more positionsrelative to the liquid-receiving surface 40 including at some timesassuming a position adjacent the liquid-receiving surface 40.

The distal edge 66 of each barrier cuff 62 is preferably disposedinboard of the proximal edge 64 in the first waist region 22 so as topresent a more effective barrier against the flow of exudates. Thedistal edges 66 may also be disposed outboard of the of the proximaledge 64 in the first waist region 22. The distal edges 66 are maintainedinboard of the proximal edges 64 in the first waist region 22 by thefirst closing means 78 so as to obviate their inversion. The firstclosing means 78 is located in a first closure zone 92 which is disposedinboard of the side flaps 58 and, in the same embodiment, or in anotherpreferred embodiment, at least a portion of the first closing means 78is positioned above at least a portion of the absorbent core 44.

As shown in FIG. 1, the distal edges 66 are preferably laterally spacedapart from each other in the first waist region 22. However, the lateralspacing between the distal edges 66 can range from being crossed overeach other to abutting each other to being laterally spaced apart up tothe width of the proximal edges in the first waist region 22. Thus, inthe embodiment shown in FIG. 1, the distal edges 66 may be laterallyspaced apart from about -25 mm (-1 inch) (overlapping edges) up to about150 mm (6 inches). Preferably, the distal edges 66 are spaced apart sothat the barrier cuff 62 will fit in the innermost leg crease of thewearer rather than ride along the wearer's outer thigh.

The distal edges 66 are also shown in FIG. 1 to be disposed parallel toeach other and perpendicular to the end edge 32 of the diaper 20 in thefirst waist region 22. While this is a preferred embodiment, the distaledges 66 may alternatively be angled toward or away from each other,preferably toward each other, such that the distal edges 66 are disposednon-perpendicular to the end edges 32. Angling the barrier cuffsrelative to the end edge 32 may assist in allowing the barrier cuff toremain spaced from the liquid-receiving surface 40 in the crotch region26 during use.

The distal edges 66 are laterally spaced apart from each other in thecrotch region 26. The lateral spacing of the distal edges 66 isespecially important in the crotch region 26 to prevent body exudates,especially urine, from leaking out of the diaper 20 in the leg regionsof the wearer. If the distal edges 66 are laterally spaced too far fromeach other, then the barrier cuffs 62 have an increased tendency to"flip out" in the crotch region 26 such that urine can flow over thebarrier cuffs 62. If the distal edges 66 are spaced too close to eachother, then the barrier cuffs 62 provide a reduced area for depositionof exudates such that exudates could be deposited directly onto thebarrier cuffs 62 and flow to the edges of the diaper 20.

The distal edge 66 of each barrier cuff 62 is disposed outboard of eachproximal edge 64 in the second waist region 24 of the diaper 20. Theterm "outboard" is defined as the direction away from the longitudinalcenterline 36 of the diaper 20 that is parallel to the respective edgeof the diaper 20 along which the barrier cuff 62 is disposed, (i.e., thedirection opposite from the direction defined by the term "inboard").Thus, the barrier cuff 62 is "flipped out" in the second waist region24. The flipped out portion of the barrier cuff 62 promotes bettercontainment that is less sensitive to application variations andprovides a contoured fit about the buttocks of the wearer. The distaledges 66 may be maintained outboard of the proximal edges 64 in thesecond waist region 24 by the second closing means 80. One skilled inthe art will appreciate that the distal edges 66 may also be disposedinboard of the proximal edges 64 in the second waist region 24.

As shown in FIG. 1, the distal edges 66 are laterally spaced apart fromeach other in the second waist region 24. However, the spacing betweenthe distal edges 66 can range such that the distal edges 66 are angledrelative to each other. The distal edges 66 are also shown in FIG. 1 tobe disposed parallel to each other and perpendicular to the end edge 32of the diaper 20. The distal edges 66 may alternatively be angled towardor away from each other, preferably away from each other, such that thedistal edges 66 are disposed non-perpendicularly to the end edges 32.

Because the distal edge 66 is disposed inboard of the proximal edge 64in the first waist region 22 and outboard of the proximal edge 64 in thesecond waist region 24, the distal edge 66 is inflected ("flipped out")along its length. Thus, the article fits the contours of the wearer'sbody. This inflection transitions the barrier cuff 62 from snuglyfitting about the buttocks (the flipped out portion) to fitting in the"no motion" zone of the legs for better containment (the stand-upportion; i.e., the distal edge 66 being disposed inboard of the proximaledge 64). The resultant inflected barrier cuff 62 is easier to apply tothe wearer and ensures that the fit of the barrier cuff 62 is in the "nomotion" zone in the crotch region 26 with a snug fit about the wearer'sbuttocks in at least the second waist region 24.

It has been found that the inflected barrier cuff 62 thus provides botha gasketing action about the buttocks of the wearer to provide a snugfit which reduces leakage of body exudates, especially runny bowelmovement, and a stand-up barrier cuff 62 in the crotch region 26 and thefirst waist region 22 to constrain, contain and hold body exudateswithin the diaper 22 along the channel (not shown). However, it has beenfound that if the barrier cuff 62 is "flipped out" too far toward thefirst waist region 22 along the length of the barrier cuff 62, then bodyexudates will tend to flow over the barrier cuffs. Thus, it is preferredthat the inflected barrier cuffs 62, in use, provide a gasketing actionabout the buttocks of the wearer to provide a snug fit (i.e., theflipped out portion of the barrier cuffs is positioned) in less thanabout 50% of the length of the diaper, more preferably less than about40% of the length of the diaper 20, and most preferably only in thesecond waist region 24. (The percent length of the flipped out portionis defined as that length of the diaper in which the barrier cuff isflipped out divided by the total length of the diaper times 100%). Thus,the stand-up portion of the barrier cuff (distal edge 66 disposedinboard of the proximal edge 64) is provided, in use, in at least about50% of the length of the diaper, preferably at least about 60% of thelength of the diaper, and most preferably from the first waist region 22to and throughout the crotch region 26.

The flipped out portion of the barrier cuff 62 can be maintained in lessthan about 50% of the length of the diaper 20 in a number of differentways. For example, the second closure zone 94 is preferably longer thanthe first closure zone 92. Alternatively, a closure attachment means maybe positioned on the barrier cuff 62 toward or in the crotch region 26of the diaper for securing the distal edge 66 inboard of the proximaledge 64 so that the flipped out portion is maintained in less than about50% of the length.

A channel (not shown) is formed between the proximal edge 64 and thedistal edge 66 of the barrier cuff 62 in the crotch region 26 and thefirst waist region 22. The channel forms a barrier to the flow ofexudates as they tend to move or float across the topsheet 38. Thechannel also contains and holds exudates within the diaper 20 until thediaper 20 can be removed.

In another embodiment of the diaper 20, the distal edges 66 of thebarrier leg cuffs 62 may be disposed outboard of the proximal edge 64 inboth the first and second waist regions 22 and 24. The leg cuffs 62 arepartially secured inward of the proximal edge 64 in the crotch region26. In this embodiment, the lower half of the leg cuff 62 is attached tothe topsheet by those methods discussed above. The distal edge 66 in thecrotch region 26 is then moved to a position approximately perpendicularto the topsheet 38 by action of the elastic members 77. This embodimentprovides a gasketing action in both the first and second waist regions22 and 24 and a stand up barrier in the crotch region 26.

In another embodiment of the alternate embodiment, the distal edges 66of the barrier leg cuffs 62 may either be disposed inboard of theproximal edge 64 in both the first and second waist regions 22 and 24 orboth disposed outboard of the proximal edge 64 in both waist regions 22and 24. The leg cuffs 62 are partially secured inward of the proximaledge 64 in the crotch region 26. In this embodiment, the lower half ofthe leg cuff 62 is attached to the topsheet in the crotch region 26 bythose methods discussed above. The distal edge 66 in the crotch region26 is then moved to a position approximately perpendicular to thetopsheet 38 by action of the elastic members 77. This embodimentprovides a gasketing action in both the first and second waist regions22 and 24 and a stand up barrier in the crotch region 26.

The barrier cuffs 62 are preferably liquid impermeable so as to preventthe strikethrough of body exudates. A liquid impermeable barrier cuff 62retards the movement of liquid through the barrier cuff 62, therebymaking it more leakage resistant. The barrier cuffs 62 may be renderedliquid impermeable in any manner well known in the art such asselectively treating the barrier cuffs or by choosing a liquidimpermeable material, such as a hydrophobic nonwoven material, for thebarrier cuffs 62.

The barrier cuffs 62 may additionally be provided with absorbent meanssecured to or within the barrier cuff 62. The absorbent means absorb andcontain exudates which contact the barrier cuff 62. The absorbent meansmay be any means which is capable of absorbing and retaining liquids andmay have any size, shape, configuration or absorbent capacity. Theabsorbent means may be disposed in the barrier cuff 62 along the inboardsurfaces of the barrier cuff 62 or within the barrier cuff 62.

A spacing means 76 for spacing the distal edge 66 away from theliquid-receiving surface 40 is any member which gathers, contracts,stiffens, shortens or otherwise acts on the barrier cuff 62 so as tocause the barrier cuffs 62 to stand up to provide a channel along thebarrier cuff 62 that acts as a constraint against the leakage ofexudates and a gasketing action about the buttocks of the wearer toprovide a snug fit.

As shown in FIG. 1, the spacing means 76 preferably comprises elasticmembers 77 operatively associated with each of the barrier cuffs 62adjacent the distal edge 66. The elastic members 77 are preferablysecured to the barrier cuff 62 in an elastically contractible conditionso that in a normally unrestrained configuration, the elastic members 77effectively contract or gather the distal edge 66 of the barrier cuff62. The elastic members 77 can be secured to the barrier cuff 62 in anelastically contractible condition in at least two ways as is discussedin U.S. Pat. No. 3,860,003 entitled "Contractible Side Portion ForDisposable Diaper" which issued to Kenneth B. Buell on Jan. 26, 1974,which is incorporated by reference herein. In addition, the length ofthe elastic member 77 in general is dictated by the diaper design. Inthe embodiment illustrated in FIG. 1, the elastic member 77 extendsalong essentially the entire length of the barrier cuff 62 in the crotchregion 26, although other lengths are cognizable.

The diaper 20 is preferably applied to a wearer by positioning thesecond waist region 24 behind the wearer's back and drawing theremainder of the diaper 20 between the wearer's leg so that the firstwaist region 22 is positioned across the front of the wearer. The endsof the tape tab fasteners 56 are then secured preferably to outwardlyfacing areas of the diaper 20. In this manner, the stand-up position ofthe barrier cuffs 62 should be disposed in the "no motion" zone of thewearer in the crotch region 26 and the flipped out portion be positionedin less than about 50% of the length of the diaper 20, preferably so asto be disposed in only the second waist region 24, so as to provide agasketing action about the buttocks of the wearer.

The Process

Having described the product in detail, the process of this invention bywhich the product is manufactured shall be discussed.

In the first embodiment, the barrier leg cuffs 62 are joined to acompleted chassis. The topsheet 38, absorbent core 44 and backsheet 42are assembled into a chassis in any conventional fashion. The topsheet38 and the backsheet 42 are associated together in any suitable manneras is well known in the diaper manufacturing art. As used herein, theterm "associated" encompasses configurations whereby the topsheet 38 isdirectly joined to the backsheet 42 by affixing the topsheet 38 directlyto the backsheet 42, and configurations whereby the topsheet 38 isindirectly joined to the backsheet 42 by affixing the topsheet 38 tointermediate members which in turn are affixed to the backsheet 42. Thetopsheet 38 and the backsheet 42 can be joined directly to each other inthe diaper periphery 28 by flap attachment means (not shown) such as anadhesive or any other attachment means as is known in the art. Thus, forexample, a uniform continuous layer of adhesive, a patterned layer ofadhesive, an array of separate lines or spots of adhesive, or a networkof adhesive filaments may be used.

After the chassis has been formed, the barrier leg cuffs 62 are joinedto the topsheet 38 of the completed chassis by their proximal edges 64as shown in FIG. 2. The term "joined" includes any means for securingthe barrier cuff 62 to the diaper 20, and includes embodiments whereinthe barrier cuffs 62 are separate members directly or indirectly securedto the side flaps 58 (i.e., integral barrier cuffs) or embodimentswherein the barrier cuffs 62 are constructed from the same member ormaterial as an element of the diaper 20 such as the side flap 58 so thatthe barrier cuffs 62 are a continuous and undivided element of the sideflap 58 (i.e., unitary barrier cuffs). The barrier cuffs 62 mayalternatively be joined to the backsheet 42, the topsheet 38, theabsorbent core 44, or any combination of these or other elements of thediaper 20. The term "joined" includes any means for securing the barriercuff 62 to the diaper 20, and includes embodiments wherein the barriercuffs 62 are separate members directly or indirectly secured to the sideflaps 58 (i.e., integral barrier cuffs) or embodiments wherein thebarrier cuffs 62 are constructed from the same member or material as anelement of the diaper 20 so that the barrier cuffs 62 are a continuousand undivided element of the diaper 20 (i.e., unitary barrier cuffs).The proximal edges 64 and topsheet 38 are joined together in anysuitable manner. As used herein, the term "joined" encompassesconfigurations whereby the proximal edges 64 are directly secured to thetopsheet 38 by affixing the proximal edges 64 directly to the side flap58 and configurations whereby the proximal edges 64 are indirectlysecured to the topsheet 38 by affixing the proximal edges 64 tointermediate members which in turn are affixed to the side flap 58. Inthe preferred embodiment, the proximal edges 64 and the topsheet 38 aredirectly secured to each other at least in the crotch region 26 by theseal means (not shown).

The seal means provides a seal along the proximal edge 64 to present abarrier to the wicking of liquids through the topsheet 38. While thetopsheet 38 or the absorbent core 44 may extend beyond the seal means,protection against leakage of liquids emanating from the edges of theabsorbent core 44 or wicking along the topsheet 38 may be enhanced bymaking the topsheet or the absorbent core not extend beyond the proximaledge 64. The seal means may be any means for securing the proximal edges64 to the side flaps 58 such as adhesives, heat/pressure sealing,ultrasonic bonding, or any other means or methods as are known in theart. Exemplary adhesives are manufactured by Findley Adhesives, Inc. ofElmgrove, Wis. and marketed as Findley Adhesive 581 or by H. B. FullerCompany of St. Paul, Minn. and marketed as HM-1258.

As illustrated in FIG. 2, after the leg cuffs 62 are joined to the bodyof the diaper 20 along the cuffs' proximal edge 64, the cuffs 62 arepositioned such that the elasticated (distal) edge 66 is orientedinwardly toward the longitudinal centerline 36 of the diaper 20. Oncethe elasticated edge 66 has been positioned inwardly toward thelongitudinal centerline 36, leg notches (not shown) can be cut andremoved without leg cuff interference.

Next, a bonding agent, as described above, is provided in the secondwaist region 24 and the cuffs 62 are attached outwardly of thelongitudinal centerline and anchored to the diaper 20. The seal means 82may be any means for securing the proximal edges 64 to the side flaps 58such as adhesives, heat/pressure sealing, ultrasonic bonding, or anyother means or methods as are known in the art. The seal means may beapplied to either the side of the leg cuff 62 outboard of thelongitudinal centerline 36 or to the side flaps 58. In either instance,once the cuffs 62 are folded outwardly, the cuffs 62 will become bondedto the diaper 20.

As shown in FIG. 2A, after the cuffs 62 are folded outwardly, anintermittent bond is applied in the first waist region 22 of the diaper20 either on the side of the barrier leg cuff 62 inboard of thelongitudinal centerline 36 or to the body of the diaper 20 itself. Thebond may be any means commonly used in the art such as adhesives,heat/pressure sealing, ultrasonic bonding or any other means or methodpresently known. The method preferably used to bond the barrier leg cuff62 to the first waist region 22 of the diaper 20 is an adhesive. Next,the diaper 20 is folded so that the barrier leg cuffs 62 become attachedinwardly toward the longitudinal centerline 36 in the first waist region22. Finally, the diapers 20 are separated from the web into individualarticles and prepared for packaging. Typically, this is performed bycutting the diapers 20 transversely.

As shown in FIG. 3, a second embodiment, the barrier leg cuffs 62 arejoined to the topsheet 38 by a continuous bond, as discussed previously.The barrier leg cuffs 62 are joined to the topsheet 38 with theirrespective distal edges 66 directed inwardly toward the longitudinalcenterline 36 of the diaper 20. A bonding agent, as described above, isthen provided in the first waist region 22 of the diaper 20. While thedistal edges 66 are directed inwardly toward the longitudinal centerline36, the distal edges 66 are anchored in the first waist region 22 of thediaper 20. This anchoring means can be any conventional means known inthe art such as adhesives, heat/pressure sealing, ultrasonic bonding orany other means or methods known in the art. Again, the anchoring meansmay be applied to either the side of the leg cuff 62 inboard of thelongitudinal centerline 36 or to the body of the diaper 20.

After the barrier leg cuffs 62 are bonded to the first waist region 22of the topsheet 38, the topsheet 38 is then associated with a backsheet42 and an absorbent core 44, in the manner described above, to form achassis.

Once the topsheet, backsheet 42 and absorbent core 44 have beenassociated (not shown), leg notches are then cut forming ear panels 100in at least the second waist region.

After the leg notches have been cut, a bonding agent is applied in thesecond waist region 24 of the diaper 20. The bonding agent can beapplied either to the side of the barrier leg cuff 62 outboard of thelongitudinal centerline 36 or to the topsheet 38 of the diaper 20 nearthe outboard side of the barrier leg cuff 62. The ear panels 100 arethen folded inwardly toward the longitudinal centerline 36 onto thebarrier leg cuffs 62. The bonding agent bonds the distal edge 66 to theear panel 100 in the second waist region 24 to the barrier leg cuff 62.The diapers 20 are then separated into individual articles and preparedfor packaging.

As shown in FIG. 4, in a third embodiment, the barrier leg cuffs 62 arefirst associated with the topsheet 38. A bonding agent is then providedin the second waist region 24 and the barrier leg cuffs 62 are securedto the topsheet 38 with their distal edges 66 directed outwardly fromthe centerline 36 in the second waist region 24 of the diaper 20. Theleg cuffs 62 are secured in the second waist region 24 of the diaper 20by any conventional means such as adhesives, heat/pressure sealing,ultrasonic bonding, or any other means or methods as are known in theart. The topsheet 38 is then associated with the backsheet 42 and theabsorbent core 44 to form a chassis. Once the chassis has been formed,the leg notches are cut. After the leg notches have been cut, thebonding agent is provided in the first waist region 22 of the diaper 20.In this embodiment, the bonding agent is applied to either the side ofthe barrier leg cuff 62 inboard of the longitudinal centerline 36 or tothe body of the diaper 20 near the inboard side of leg cuff 62 in thefirst waist region 22 of the diaper 20. Thus, when the diaper 20 isfolded the front bond is secured. The sequence of the third embodimentdiffers from that which is described in the second embodiment in thatthe bond in the second waist region 24 is completed first. After thediaper 20 has been folded, the diapers 20 are then separated andprepared for packaging.

In a fourth embodiment, shown in FIG. 5, the leg cuffs 62 are attachedto the topsheet 38 with the distal edge 66 of each leg cuff 62 directedoutwardly from the centerline 36 of the article 20. As the cuffs arebeing attached, the cuffs 62 are secured to the topsheet 38 outboard ofthe longitudinal centerline 36 in both the first and second waistregions 22 and 24. In an alternate embodiment of this embodiment, theleg cuffs 62 can be attached to the topsheet 38 with the distal edge 66of each cuff 62 directed inwardly toward the centerline 36. The topsheet38, absorbent core 44 and backsheet 42 are then assembled into a chassisin any conventional fashion, as described above. After the diaper 20 hasbeen assembled, the leg notches are then cut. Next, an adhesive isprovided on the proximal half of the inboard side of the barrier legcuff 62 in the crotch region 26. The diaper 20 is then folded and cuttransversely to its proper length. In this embodiment, when the diaper20 is opened by the consumer, the leg cuffs 62 are partially joined tothe topsheet 38 in the crotch region 26, i.e., they are secured to thetopsheet from the proximal edge 64 to approximately half their height,and joined with their distal edges 66 directed outwardly of thelongitudinal centerline 36 in both the first and second waist regions 22and 24. When the alternate embodiment is opened, the leg cuffs 62 aredirect inwardly toward the longitudinal centerline in both the first andsecond waist regions 22 and 24.

Having described the processes of this invention in detail, a generalsummary is provided in FIG. 6. FIG. 6 presents a schematic illustrationof the process of this invention. One skilled in the art should notethat slight variations occur in the various embodiments so that certainsteps may or may not be included in each embodiment. The web 200 can bean assembled chassis, as illustrated in the process accompanying FIG. 2,a topsheet 38, as illustrated in the process accompanying FIGS. 3-5, ora back sheet 42. The web 212 of the leg cuffs 62 are attached to the web200. The leg cuffs 62 can be attached either from a single web which issubsequently split into two separate webs to create each of the legcuffs or each of the leg cuffs 62 can be attached from a separate web ofmaterial. These leg cuffs 62 may be either elasticized or nonelasticized and are preferably elasticized. Although described herein asbeing attached to the completed chassis or to the topsheet 38, oneskilled in the art will appreciate that the leg cuffs 62 can also beattached to the back sheet 42. At this point, the barrier leg cuffs 62are joined to the topsheet 38 by their proximal edges 64. They can beattached by any conventional means such as adhesives, heat/pressuresealing, ultrasonic bonding, or any other means or methods as are knownin the art.

Once the leg cuffs 62 have been attached to the topsheet 38, a bondingagent is applied at station 220. The bonding agent is applied in thefirst waist region 22 as illustrated in FIG. 3. As illustrated in FIGS.2 and 4, the bonding agent is applied at station 220 in the second waistregion 24 of the diaper. In the embodiment described in FIG. 5, thebonding agent is applied to both the first waist region 22 and thesecond waist region 24 at station 220. As previously described, thisbonding agent can be any bonding agent commonly used in the artincluding, but not limited to, adhesive tape, heat sealing, pressuresealing, ultrasonic bonding or a spot adhesive and is, preferably, aspot adhesive.

Once the bonding agent has been applied to the diaper 20, at station 230the leg cuffs 62 are attached to the top sheet 38 with the cuffs 62either directed outwardly from the longitudinal centerline 36 in thesecond waist region 24, as described in FIGS. 2 and 4 or directedinwardly of the longitudinal centerline 36 in the first waist region 22as described in FIG. 3. In the embodiment depicted in FIG. 5, the legcuffs 62 will either be attached to the topsheet 38 with the distaledges 64 directed toward the longitudinal centerline 36 in both thefirst waist region 22 and the second waist region 24 or with the distaledges 64 of both leg cuffs 62 directly outwardly of the longitudinalcenterline 36 in both the first waist region 22 and the second waistregion 24. One skilled in the art will appreciate that if the bondingagent is heat sealing, pressure sealing, ultrasonic bonding or a similarmethod, that station 220 and 230 may either be combined into one stationor switched in their order in the process.

If the web 200 is not a chassis, and is either a topsheet 38 orbacksheet 42, the chassis is formed at station 240. At this point, thetop sheet 38 is associated with the absorbent core 44 and the backsheet42, as described above. Once associated, the topsheet 38, backsheet 42and absorbent core 44 form a completed chassis. The three elements,topsheet 38, backsheet 42, and absorbent core 44, are combined atstation 240 from separate webs of each or from any combination of thethree.

Once the chassis has been assembled, the leg notches are cut at station250.

Having cut the leg notches, a bonding agent is applied in the waistregion of the diaper 20, opposite to that region in which the bondingagent was applied at station 220, at station 260. For the embodimentdescribed in FIGS. 2 and 4, the bonding agent is applied in the firstwaist region 22 of the diaper 20. For the embodiment described in FIG.3, the bonding agent is applied in the second waist region 24 of thediaper. Finally for the embodiment described in FIG. 5, the bondingagent is provided on the proximal half of the inboard side of thebarrier leg cuff 62 in the crotch region 26. Again, this bonding agentcan be any bonding agent commonly used in the art including, but notlimited to, adhesive tape, heat sealing, pressure sealing, ultrasonicbonding or a spot adhesive and is, preferably, a spot adhesive.

After the bonding agent has been applied at station 260, the diapers arefolded at station 270 so that the bonding agent applied at station 260joins the leg cuffs to the topsheet 38 in the proper position. Atstation 270 the diapers may either be C-folded or Z-folded, withZ-folding being preferred. In the process described in FIGS. 2 and 4,when the diaper is folded, the bonding agent contacts the leg cuffs 62in the first waist region 22 of the diaper 20 to secure it to thetopsheet 38 directed inwardly toward the longitudinal centerline 36. Asillustrated in FIG. 3, the diaper is folded so that the leg cuffs 62become joined to the topsheet 38 directed outwardly of the longitudinalcenterline 36 in the second waist region 24 of the diaper 20. For theembodiment described in FIG. 5, the diaper 20 is folded so that the legcuffs 62 becomes secured to the diaper 20 in the crotch region 26providing a partial standup barrier in the crotch region 26. One skilledin the art will appreciate that if the bonding agent is heat sealing,pressure sealing, ultrasonic bonding or a similar method, stations 260and 270 may either be combined into one station or switched in theirorder in the process.

To avoid any cross machine direction complications, the consumertechnically completes the construction of the diaper 20. When ready touse the diaper 20 after purchase, the consumer opens the diaper 20 to aposition in which the barrier leg cuffs 62 are attached in the firstwaist region 22 of the diaper 20 with their distal edges 66 directedinwardly toward the longitudinal centerline 36 and in which the distaledges 66 are directed outwardly of the longitudinal centerline in thesecond waist region 24, for the embodiments described in FIGS. 2-4. Forthe embodiment described in FIG. 5, the consumer opens the article to aposition in which the barrier leg cuffs 62 have their distal edges 66directed either inwardly toward the longitudinal centerline 36 in bothwaist regions, 22 and 24, or directed outwardly of the longitudinalcenterline 36 in both waist regions, 22 and 24, and in which the diaper20 has a partial standup barrier in the crotch region 26.

As a final step, the web 200 is cut into individual diapers.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method for making a wearable, absorbent articlehaving a longitudinal centerline comprising the following order ofsteps:(a) providing an absorbent web of indefinite length, the webhaving a topsheet, a backsheet, and a centrally positioned absorbentcore between the topsheet and backsheet forming a chassis, the chassishaving a first waist region, a second waist region, and a crotch regionbetween the first and second waist regions; (b) attaching a pair oflongitudinally extending barrier leg cuffs to the chassis, each of thebarrier leg cuffs having a proximal portion fixed to the topsheet and adistal portion unsecured at least to a portion of the chassis, such thatthe distal portion of each barrier leg cuff is oriented inwardly towardthe longitudinal center line of the chassis; (c) cutting leg notches inthe crotch region of the chassis; (d) attaching the barrier leg cuffs tothe second waist region of the chassis, causing the distal portion ofthe leg cuff to be attached outwardly from the longitudinal centerlinein the second waist region; (e) folding the chassis and securing thebarrier leg cuffs to the topsheet in the first waist region of thechassis with their distal portions extending inwardly toward thelongitudinal centerline in the first waist regions; and (f) cutting theweb transversely into individual articles, wherein the steps occur in asingle machine direction.
 2. The method of claim 1 wherein the step ofattaching comprises securing by a method selected from the groupconsisting of adhesive bonding, heat sealing, pressure sealing, andultrasonic bonding.
 3. The method of claim 1 wherein the step ofattaching comprises using a spot adhesive.
 4. The method of claim 1wherein the step of securing comprises securing on a side, farthest fromthe longitudinal centerline, of the leg cuff in the second waist regionof the chassis.
 5. The method of claim 1 wherein the step of attachingcomprises securing on a side, closest to the longitudinal centerline, ofthe leg cuff in the first waist region of the article.